Stabilized 14lb

ABSTRACT

Storage-stable 141b prepared by contacting 141b with alumina at temperatures of about 0-100 degrees Centigrade, compositions containing the thus treated 141b, and uses thereof for the production of polyurethane and polyisocyanurate foams.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of copending application Ser.No. 07/863,611, filed Apr. 6, 1992.

FIELD OF THE INVENTION

This invention relates to methods for rendering1,1-dichloro-1-fluoroethane ("141b") storage-stable and, for blowingagent applications, stable against decomposition in polyol formulationsor the corresponding polyurethane or polyisocyanurate foams madetherefrom. More particularly, it relates to the use of alumina tostabilize 141b against decomposition during storage or use.

BACKGROUND OF THE INVENTION

Much attention has been focused on 141b in recent years as a replacementfor CFC-11 (trichlorofluoromethane) as a foam blowing agent, as asolvent, and so forth. In the manufacture of 141b, however, such as bythe reaction of hydrogen fluoride with 1,1,1-trichloroethane orvinylidene chloride ("VDC"), unwanted impurities such as unsaturatedcarbon compounds (including VDC) have been found to result. Thus,processes have been developed for removing VDC from 141b viaphotochlorination, such as disclosed in U.S. Pat. No. 4,948,479.

It has now been found, however, that even with such a purificationprocedure 141b can be unstable in storage, resulting in the formation ofsuch unwanted by-products as phosgene. Thus, the industry is in need ofa means for producing storage-stable 141b.

As noted in U.S. Pat. No. 5,135,680, 141b also has stability problems inblowing agent applications. As there stated, "Polyurethane andpolyisocyanurate foams are conventionally prepared by reacting anorganic polyisocyanate (including diisocyanate) `A-side` component witha `B-side` polyol premix component containing organic polyol, blowingagent, surfactant, catalyst, and possibly other additives such as flameretardants, antioxidants, and U.V. stabilizers. These A-side and B-sidecomponents may be purchased by the end-user in separate containers andstored for later use. Since decomposition of the HCFC blowing agents hasbeen observed in the B-side premixes during storage and during theprocess of making the foam, HCFC compositions inhibited against suchdecompositions would be highly desirable. For example, the preferred141b blowing agent has been observed to decompose during the foam-makingprocess to up to about 1%, depending on the formulation and reactionconditions, of various decomposition products of which by far thepredominant product is 1-chloro-1-fluoroethylene ("1131a"). Inhibitionof such decomposition is desired both because of toxicity concerns andbecause the decomposition is accompanied by the formation of equivalentamounts of acid which in turn causes catalyst deactivation."

SUMMARY OF THE INVENTION

This invention is directed to a method for rendering 141b storage-stablewhich comprises contacting said 141b with alumina at a temperature offrom about 0 to 100 degrees Centigrade (preferably about 20-40 degrees);to the resulting storage-stable 141b compositions comprised of 141balone or 141b in a premix composition containing a polyol and,optionally, other ingredients such as surfactants, catalysts, and flameretardants; to foamable compositions containing 141b, polyol, andpolyisocyanate; to methods of making foam from such compositions; and tothe resulting foams.

DETAILED DESCRIPTION OF THE INVENTION

It has now been found that 141b is stabilized against decompositionduring storage by treatment with alumina. Particularly surprising is thediscovery that alumina is effective both to remove any phosgene alreadyformed and to prevent its reoccurrence during storage. In contrastthereto, the removal of phosgene from 141b with a sodium hydroxidesolution does not prevent the reoccurrence of phosgene during storage.Equally surprising is the discovery that the thus-treated 141b isstabilized, without the need for added inhibitors, against thedecomposition into 1131a for blowing agent applications.

While any alumina may be used and no specific crystalline structure isrequired, it is preferred to use alumina having a high surface area suchas is found in activated alumina. Examples 1 and 2 below demonstrate theeffectiveness of a variety of commercially available activated aluminas.

The 141b can be treated batchwise or continuously, such as by passingthe 141b over a bed of alumina.

The temperature can range from about 0 to about 100 degrees Centigrade,preferably from about 20 to about 40 degrees. Higher temperatures canlead to the formation of unwanted decomposition products, while at lowertemperatures the rate of adsorption of phosgene can be significantlyslower.

The contact time can vary from a matter of seconds to 48 hours or more.The optimum time varies with the method of contact, the size of thealumina bed, the 141b flow rate, the phosgene level (if any) in the141b, and so on, as can readily be determined by one skilled in the art.

The method is demonstrated below for treating 141b in the liquid state,but should also have utility for treating 141b while in the gas state.

The invention was illustrated in the following examples using a "pure"141b made by a process such as taught in U.S. Pat. No. 4,948,479, i.e.,by reacting hydrogen fluoride and 1,1,1-trichloroethane,photochlorinating, and distilling. Typical product analyses are given inTable 1 of that patent. The invention is, however, equally applicable to141b made by other processes, such as by reacting HF with vinylidenechloride.

Example 1--A "purified" liquid 141b (120 grams) in which phosgene hadalready formed upon storage to a level of about 12 ppm was mixedbatchwise with 50 grams each of a variety of commercially available,dried, activated aluminas (La Roche's A201 and A204, Alfa Thiokol'sgamma alumina, Harshaw's Al 4126, and Alcoa's 5×7 LDS) for one-half hourat room temperature (about 22 degrees Centigrade). Analysis forphosgene, which was carried out spectrophotometrically using4-(p-nitrobenzyl)-pyridine, showed that in each case the phosgene wasreduced to less than 3 ppm.

Example 2--In this example 141b having a level of about 14 ppm ofphosgene was fed at a rate of 20 ml/min. at room temperature throughbeds (85 grams each) of a variety of dried, activated aluminas (LaRoche's 210, 202, 204.1, and 204.4) loaded in a 100 ml burette. Thecontact time was about 5.3 minutes. For each of the 4 aluminas tested,analysis of the treated 141b showed phosgene levels of less than 0.4ppm.

Example 3--The alumina-treated 141b from Example 2 was subjected to U.V.irradiation for four hours in the presence of air since five hours ofsuch irradiation have been found to simulate one year of aging atambient temperature. Analysis showed no evidence of phosgene formation.In contrast, when untreated 141b was irradiated, 20 ppm of phosgene wereformed.

Example 4--Example 2 with La Roche 204.4 alumina was essentiallyrepeated except that only 8 grams of activated alumina was used andcontact times of 0.53 and 0.26 minute were tried. At 0.53 minute thephosgene was again reduced to 0.4 ppm or less; at 0.26 minute thephosgene was reduced to about 1 ppm.

For blowing agent applications the 141b can also be incorporated intocompositions containing a polyol or a fully formulated B-sideformulation containing a polyol, catalyst, surfactant, and, optionally,other additives. Typical polyols are, for example, Stepanol PS 2502A, anaromatic polyester polyol sold by the Stepan Company; Terate 203, anaromatic polyester polyol sold by Cape Industries; Pluracol Polyol 975,a sucrose-based polyol sold by BASF; Poly-G 71-530, a polyether polyolsold by Olin; and Quadrol, an amine-based polyol supplied by BASF.Typical catalysts include Potassium HEX-CEM, a potassium octoate sold byMooney Chemicals; Polycat 41, anN,N,N-tri(dimethylaminopropyl)cyclohexatriazine sold by Air Products;Polycat 8, an N,N-dimethylcyclohexylamine amine sold by Air Products;Dabco TMR-30, a 2,4,6-tri(dimethylaminomethyl)phenol supplied by AirProducts; and Dabco K-15, a potassium 2-ethylhexoate in diethyleneglycol supplied by Air Products. A typical surfactant is Dow Corning193, a silicone polymer. A typical A-side component is Mondur E-489, anaromatic diisocyanate supplied by Miles Inc., or Lupranate M20S, apolymethylene-diisocyanate supplied by BASF.

Example 5--Polyurethane foams were prepared using untreated 141b and141b which had been treated with La Roche 204.4 alumina at roomtemperature for 5 minutes. In each case the foam was prepared bystirring a formulation containing polyol (100 g of Stepanol PS 2502A),141b (25.8 g), surfactant (1.51 g of Dow Corning 193), catalyst (2.82 gof Potassium HEX-CEM and 0.7 g of Polycat 41), and diisocyanate (127.2 gof Mondur E-489). The hot foam was left to cool to room temperature forabout one hour. After curing the foam at 250 degrees Fahrenheit for 20hours, the foam cell gas was analyzed by crushing a sample cut from thecenter of the foam and injecting the released gas mixture directly to agas chromatograph. The cell gas of the foam made from the untreated 141bwas found to contain 2587 ppm of 1131a, while the cell gas of the foammade from alumina-treated 141b contained only 820 ppm of 1131a.

What is claimed is:
 1. A method of making foam which comprises mixing astorage-stable 1,1-dichloro-1-fluoroethane, resulting from contacting1,1 dichloro-1-fluoroethane with alumina at a temperature of from about0 to about 100 degrees centigrade, with a polyol and a polyisocyanate.2. The foam produced by the process of claim 1.